Operator s Instruction Manual

Transcription

1 Aussie Cobra Series Drain Cleaning Jetters (Skid Mount) November 2012 Operator s Instruction Manual Ref : ACOBRASKMANVER1 Operators must read this manual and understand it before operating this machine November 2012 Aussie King Cobra & Cobra Drain Cleaner Operator s Manual 1

2 Aussie Pumps AUSSIE DRAIN CLEANING JETTER RISK ASSESSMENT MODELS: In line with the National Occupation Health & Safety Commission s requirements the data below applies to the Aussie Cobra series of skid mounted drain cleaning models:, Aussie Cobra, Aussie King Cobra, Aussie Python DESCRIPTION: Engine drive high pressure drain cleaning jetters designed for both domestic and professional cleaning applications. MATERIAL CONSTRUCTION: Aussie drain cleaning jetters are mounted on heavy duty steel skids. They consist of a quality internal combustion petrol or diesel engine driving a triplex style three piston high pressure pump. The machines can be supplied with hose reels and up to 60 metres of sewer hose to increase operator convenience. RISK RANKING METHOD: Risk is the combination of the likelihood of a specific unwanted event and the potential consequences if it should occur. PROBABILITIES: A. Common or repeating occurrence. B. Known to occur or it has happened. C. Could occur, or I ve heard of it happening. D. Not likely to occur. E. Practically impossible. CONSEQUENCES FOR PEOPLE: 1. Fatality or permanent disability. 2. Serious lost time, injury or illness. 3. Moderate lost time, injury or illness. 4. Minor lost time, injury or illness. 5. No lost time. RISK RANKING METHOD: For each event, the appropriate probability (a letter A to E) and consequences (a number 1 to 5) is selected. RISK RANKING TABLE: The consequences (loss outcomes) are combined with the probability (of those outcomes) in the risk ranking table to identify the risk rank of each loss event (e.g. a consequence of 3 with a probability of B yields a risk rank of 9). The table yields a risk rank from 1 to 25 for each set of probabilities and consequences. A rank of 1 is the highest magnitude or risk that is a highly likely, very serious event. A rank of 25 represents the lowest magnitude of risk, an almost impossible very low consequence event. Controls must be taken to either eliminate or minimise the risk. C O N S E Q U E N C E PROBABILITY A B C D E PLAN SAFE. STAY SAFE Page 2 Aussie Cobra Series Skid Mount Drain Cleaner Operator s Manual Nov 12

3 POTENTIAL HAZARD: Aussie Pumps Hazard Yes/No Risk Risk Rating Controls Entanglement with sewer hose (tripping, falling) Yes Personal injury of the operator or bystanders 13, Warning stickers, hose reel option Injury from high pressure water Yes Personal injury of the operator or bystanders 13, Warning notice on jetter, Warning in Operator s Manual,, Use of safety protection clothing (Aussie Pro-operator), Use of barriers to keep bystanders away from work area Injury from whipping hose if jetter run with hose out of drain Yes Personal injury of the operator or bystanders 13, Warning in operator s manual, Warning sticker on jetter Suffocation Yes Fatality is the risk 7, Machine decal warning about operation in confined spaces, Operator training in working in confined spaces Ergonomic lifting or movement on site, including drain covers High temperature (from engine muffler and other components) Battery exploding if not charged correctly Yes Personal injury 8, Machine decal warning about correct lifting procedures, Operator s Manual, Staff training, Long handled drain cover keys Yes Burns from muffler 15, Warning sticker on machine Yes Acid burns 12, Warning stick on battery, Wear eye & face protection when working near battery Yes Serious injury, burns 8, Warning sticker on machine Fire or explosion caused by refuelling engine while running Noise Yes Hearing damage 15, Warning sticker regarding ear muffs to be used during operation Dislodged particles in Yes Sight damage 6, Warning regarding wearing safety atmosphere glasses. Slipping on wet surface Yes Personal injury 9, Use of proper footwear Contact with foul water or sewage Contact with chemical cleaners used to clean drains Yes Yes Infection, illness from water splashes, ingested water Skin contact could result in burns, skin irritation etc. Fumes from some chemicals may lead to respiratory problems 9, Personal protective equipment, ie gloves, overalls, boots, eye and/or face protection etc, Operator to use good basic hygiene 4, Chemical cleaners to only be used as a last resort when other methods have failed., Areas to be kept well ventilated., Staff to follow manufacturers instructions at all time for use, storage & disposal., Staff to wear the appropriate PPE, Respiratory protection when required Signed originator... Job title... Date Completed... Aussie Pro-Operator gear Good to 500 BAR (7,300 PSI) THE PROTECTION YOU NEED! Nov 12 Aussie Cobra Series Drain Cleaner Operator s Manual Page 3

4 Contents AUSSIE DRAIN CLEANING JETTER RISK ASSESSMENT... 2 Warranty Coverage... 4 STAY SAFE... 5 Safety Clothing... 5 Engine Hazards... 5 Jetter Hose Warning. IMPORTANT... 5 Wash Down Operation... 5 Bacteria Warning... 5 SAFETY PRECAUTIONS... 6 Work Area Safety minimise hazards... 6 Specifications... 7 Accessory Identification... 7 Assembly & Preparation for Use... 8 ASP System... Aussie Safety Protection System... 8 Start Up & Operation... 9 Operation as a Drain Cleaning Jetter... 9 Operation as a High Pressure Washer High Pressure Piston Pumps & Plumbing Personal Protective Equipment STAY SAFE Operating Tips Nozzle Selection Operator s Hand Signals Accident Reporting Emergency Medical Information Service Record Maintenance, Service and Spares Troubleshooting Guide Pump Kits Replacement Parts Warnings Pressure Cleaner Daily Check List Six Month (25 hours of use) Regular Service Thank you for purchasing an Aussie Cobra Drain Cleaning Jetter We want you to get the best results from your new machine and operate it safely. This manual contains information on how to do that, please read it carefully before operating the machine. Please note that drain and sewer cleaning procedures must be followed carefully. Failure to do so may result in severe injury or even death. Appropriate safety clothing and equipment must be used at all times. Aussie Pumps The Aussie Cobra series of drain cleaning jetters use water at high pressure to clear blockages such as grease, sediment and tree roots from drains. The pressure is generated by restricting the flow of water with a nozzle at the end of an extremely flexible sewer hose. The nozzle has reverse facing high pressure jets of water that propel the hose along the drain clearing blockages and flushing away the debris. Warranty Coverage Engine Aussie Pumps is proud to use engines from the world s best engine manufacturers. These engines carry a full 3 year international warranty backed up by their extensive dealer network; Honda Briggs & Stratton Kohler Please refer to the engine manual for the full terms and conditions of the engine warranty and your responsibilities of ownership. If a problem should arise or if you have any questions about your engine, consult an authorised service agent. Check online for your nearest engine dealer. Pump The Bertolini pump fitted to the drain cleaning jetter has a three year warranty, providing it is serviced by an authorised service agent every six months or 25 hours of use, contact Aussie customer service on Keep your receipt as proof of purchase and all service receipts to maintain this warranty. This guarantee is invalid if the product is found to have been abused in any way, or not used for the purpose for which it was intended. Battery The pre-charged battery fitted to your jetter is an Absorbed Glass Mat dry cell battery with a full one year warranty from the battery manufacturer. For service contact your DEKA Battery agent via Ryde Federal Batteries, , Other Components The Aussie Cobra drain cleaning jetter components have a two year warranty from date of purchase. High pressure accessories carry a 3 month warranty. The warranties cover any defect which occurs due to faulty workmanship or material under normal use. This warranty specifically excludes the following:, Damage resulting from debris or mineral deposits contained within the water supply to the machine. Page 4 Aussie Cobra Series Skid Mount Drain Cleaner Operator s Manual Nov 12

5 , Leaking hoses when the outer cover of the hose has been abraded or the hose has been kinked., Damage to o-rings and valves, etc. caused by the use of cleaning chemicals or compounds., Replacement of parts damaged due to fair wear and tear., Misuse, negligence, alteration, accident or breakage., Failure of the machine due to lack of normal maintenance services (The owner is responsible for the performance of regular maintenance services, as specified in the Operator's Manual)., Damage and/or progressive damage caused by the failure to inform Australian Pump Industries Pty Ltd, or the closest Authorised Australian Pump Agent or Distributor, within seven days of the defect becoming apparent., Repair or modification by an unauthorised service person. Aussie Pumps Engine Hazards Engines emit toxic poisonous carbon monoxide gas which is a colourless, odourless gas. Do not run the jetter in an enclosed area. Petrol is extremely volatile and explosive under certain conditions. Please note the following:, Turn off engine and allow to cool before refuelling., Refuelling of the unit must be done in a careful manner. Do not overfill the fuel tank. Use suitable equipment for refuelling (suitable containers and funnels). Once the unit is refuelled, please ensure that the fuel tank lid is closed properly and securely. Parts of the engine will get hot when it is running. These hot surfaces can cause burns and fire. Keep body parts aware from hot areas and beware that these parts will take time to cool down. Refer page 3. Routine maintenance is the owner s responsibility. Failure to maintain the machine in line with the services outlined on the back page will invalidate warranty. Australian Pump Industries Pty Ltd specifically excludes from warranty responsibility any consequential loss or damage including on-site servicing, loss of time, loss of use of the machine, hire costs of a replacement machine or inconvenience. Where possible return faulty goods to the place of purchase. No products can be returned to us without prior permission. The reason for return must be clearly stated. N.B. Warranty is not transferable to third parties in the event of sale of the machine within the warranty period. Please note that any parts used in warranty repairs are guaranteed for a period limited by the original warranty of the parent product. Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a replacement or refund for a major failure and for compensation for any other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure. The benefits under the Aussie Pump warranty are in addition to other rights under Australian Consumer Law. STAY SAFE Safety Clothing All persons operating the unit must wear protective clothing such as safety goggles, face shields, gloves, overalls or raincoat, steel cap boots and ear protection equipment as appropriate. Refer to page 3. Jetter Hose Warning. IMPORTANT Before starting up your Aussie Cobra drain cleaning jetter, ensure that your high pressure jetting hose has been placed in the sewer line (minimum 2 metre). This must be done before starting and engaging pressure to hose reels. If this is not followed, severe injury or death may occur. The sewer hose has been marked at 1m, 2m and 3m from end of the hose. This ensures that the operator is aware that he is getting near to the end of his sewer hose as it is being removed from the drain or sewer line. Before removing the last two metres of sewer hose from the sewer line or drain pipe, water pressure to the nozzle must be shut off. Severe injury or death may occur if this procedure is not followed. Refer page 3. Wash Down Operation Whilst using your jetter for wash down with the gun and lance, do not spray any persons or animal. Severe injury or death may result if this procedure is not followed. Refer page 3. Bacteria Warning Sewer lines and drainpipes can carry bacteria and other dangerous micro-organisms which may be infectious. These may cause severe illness or death if exposed to person s mouth, nose, ears, eyes, hands or open cuts and abrasions. To protect the operator against these infectious micro-organisms or bacteria, it is imperative that arms, hands and other areas of the body must be washed after working with sewer lines with hot soapy water. Refer page 3. Do not smoke or eat while using the jetter as this may lead to the transfer of dangerous micro-organisms into the body. Nov 12 Aussie Cobra Series Drain Cleaner Operator s Manual Page 5

6 Aussie Pumps SAFETY PRECAUTIONS Everyone who uses a high pressure jetter must be competent to do so. 1. Never direct the spray jet at any person or animal. 2. Never direct spray jet at any surface that may contain asbestos. 3. Do not operate the jetter with the hose end outside of the drain. The hose can whip out of control and cause injury. Skin can be penetrated by high pressure water jets. 4. Never hold a finger over the high pressure nozzle. 5. Never direct the spray jet at the machine itself or any electrical equipment. 6. After use, release the pressure in the high pressure hose by operating the pistol trigger. 7. When not in use always switch off the engine and disconnect from water supply. 8. Certain engine components become very hot when in use, e.g. exhaust muffler and cylinder head. Switch off the engine and ALLOW TO COOL before touching. 9. Do not attempt any mechanical repair. If you have a problem with your machine contact your local dealer or Aussie Pumps service division, phone Never supply any liquid other than clean water to the water inlet. 11. Never pull the high pressure hose if it has formed kinks or nooses. Never pull the hose over sharp objects and do not allow the hose to be driven over. A damaged hose must be professionally repaired or replaced. 12. Use in a well-ventilated area. 13. Ensure unit is operated on a level surface; wheels should be chocked before use, if applicable. **** IMPORTANT **** COMPLETE A RISK ASSESSMENT OF THE SITE AND JOB BEFORE YOU START. A risk assessment form has been included at the beginning of this manual for your convenience. 17. Stay alert and pay attention to what you are doing and the machine you are operating. Do not use jetter while you are tired or under the influence of drugs, alcohol or medication. Work Area Safety minimise hazards Keep work area clean and well lit. Set up the jetter and work area in such a way as to reduce the risk of injury from high pressure water, chemical burns, infections, carbon monoxide and other causes. Mark off the area with barriers if necessary to keep bystanders, passing traffic and non-essential personal away. Check for flammable or poisonous liquids, vapours and dust that may ignite. Do not operate jetter until the area has been made safe. Check the condition of the drains before starting to jet. Drains that are in good condition will not be damaged by the jetting process. Poorly maintained or constructed drains may result in jetting being less effective and could lead to further damage to the drain. Aussie Pro-Operator 500 BAR PROTECTION, Overalls, Aprons, Jackets, Trousers, Gloves Check page 11 for details 14. Do not attempt to disconnect any hose or coupling with pressure still in the hose. 15. Do not operate the machine whilst standing on ladders; use a platform tower or scaffolding. 16. Use safety goggles when using the machine, particularly with the sand blasting attachment, or any application where loose particles of stone or grit, etc, may be blown around by the high pressure spray. Page 6 Aussie Cobra Series Skid Mount Drain Cleaner Operator s Manual Nov 12

7 Specifications Aussie Pumps Cobra King Cobra (Honda) King Cobra (Vanguard) King Cobra (Kohler) Python (pump motor group) Drain size Up to 8 Up to 8 Up to 8 Up to 8 Up to 8 Max water delivery 20 lpm 20 lpm 25 lpm 25 lpm 31 lpm Max Output 4,300 psi 5,000 psi 5,000 psi 5,000 psi 4,300 psi pressure Engine model Honda 21HP GX630 Honda 28HP GX690 Vanguard 27HP Kohler 23HP Vanguard 35HP or Kohler diesel Fuel Petrol Petrol Petrol Diesel Diesel Cooling Air Air Air Air Air Starting system Electric start Electric start Electric start Electric start Electric start Battery Dry cell Dry cell Dry cell Dry cell Dry cell Pump Bertolini TTL2030 Bertolini RAL2035 Bertolini RAL2535 Bertolini RAL2535 Bertolini RAS4482 RPM Hose supplied 60m x ¼ 60m x ¼ 60m x ¼ 60m x ¼ Optional Drain Cleaning Nozzles Supplied Aussie Jetters Nozzle Box Aussie Jetters Nozzle Box Aussie Jetters Nozzle Box Aussie Jetters Nozzle Box Optional Accessory Identification Jetter Accessories The Aussie Jetter is equipped with the following jetting accessories: 1 x Aussie steel hose reel (option with Python) 60 metres of 5,000 psi rated ¼ ID R8 sewer cleaning hose with quick fit snap on connection on outlet. Aussie Jetter Nozzle box (not supplied as standard Python); 1 x Penetrator nozzle with 3 rear jets and 1 forward jet, Wash down kit 1 x heavy duty wash down gun with 400mm stainless steel lance & high pressure nozzle. Aussie Viper Mini reel (optional) Mobile hose reel fitted with either ¼ high pressure sewer hose or 3 / 16 lightweight sewer hose. 1 x Negotiator nozzle with 6 rear jets and 1 forward jet. 1 x Aussie Root Mulcher rear turbine root cutter. 1 x Compressor nozzle 1 x spare snap on coupler 1 x tip cleaner & allen key for nozzle disassembly All nozzles suited for the sewer hose come with quick fit snap on tail for connection of hose. Please check that all accessories are supplied carefully as claims will not be accepted seven (7) days after purchase date. Optional Accessories a) Extra hose lengths in various widths, ¼, 3 / 16 & ⅛. b) Extra nozzles (see Nozzle Selection page 13). c) Super worm hose, ⅛ super flexible hose, ideal for small drains & tight bends. Complete with compressor nozzle quick fit tail. Nov 12 Aussie Cobra Series Drain Cleaner Operator s Manual Page 7

8 Aussie Pumps Assembly & Preparation for Use Pump / Gearbox / Engine 1. Check the oil in the pump, gearbox & engine Note there are separate oil reservoirs for the pump and gearbox. With the machine on a level surface, the pump oil level should cover the red spot in the oil level sight glass on the side of the pump. Pump breather Water Supply, Connect supply hose to tap and fill tank with water., The supply tank is fitted with a low water cut out. The engine will not run if the water level drops below this point. Inlet filter, To prevent the ingress of foreign bodies into the pump the jetter is fitted an Aussie Pump Saver Filter. Check filter regularly and rinse element. (See Pressure Cleaner Daily Check List on page 20.) **** IMPORTANT **** Oil loses its lubricity over time. Change pump & gearbox oil every 3 months during regular service Gearbox sight glass Pump sight glass Inlet filter FAILURE TO CARRY OUT REGULAR M AINTENANCE VOIDS WARRANTY! If necessary, top up with SAE 75W-90 oil (nonfoaming type). Do not mix different grades of oil as this may affect the machine s performance. If alternative oil is used, first empty out oil by unscrewing drain plug in bottom of machine. 2. Ensure breather plug is fitted to pump (red). 3. Note that the gearbox has a separate oil reservoir. Gearbox oil is SAE 80W90 gear oil. 4. Check engine oil level. Refer to engine manufacturer s separate handbook. ASP System... Aussie Safety Protection System Safety valve Unloader valve **** IMPORTANT **** WARNING... ALTERING OF HIGH PRESSURE PUMPING SYSTEM MAY RESULT IN SEVERE INJURY OR DEATH. Warranty will be void if any high pressure equipment has been altered by unauthorised persons. Over-speeding or over-pressurizing of pumping system can be very dangerous and severely reduce the life of your Aussie Cobra Drain Cleaning Jetter and may result in injury or death. BOTH FACTORY SET DO NOT ADJUST DO NOT allow machine to run on by-pass for more than 2 minutes. AUSSIE SAFETY VALVE: This device blows off excess pressure if unloader has been tampered with, thus protecting the pump. Do not tamper with pre-set unloader and safety valve. (This will void your warranty.) Page 8 Aussie Cobra Series Skid Mount Drain Cleaner Operator s Manual Nov 12

9 Start Up & Operation Operation as a Drain Cleaning Jetter Aussie Pumps The ball valve on the jetter acts like the trigger on a high pressure spray gun. Ensure it is in the off position before starting the engine. 1. Open breather vent in fuel tank cap. 4. Start the engine. Ensure fuel tap is open, choke is fully open and turn the key or pull the starter rope to start engine. (Refer to engine manual for more information). Ensure fuel tap is open, choke is fully open and turn the key or pull the starter rope to start engine. (Refer to engine manual for more details). Adjust throttle speed as required. 5. Check for leaks in the line connections. All leaks must be fixed before using the jetter. 6. Turn on ball valve to activate high pressure jet to nozzle. 7. Start jetting. Ease the hose down the drain. Twist the hose to aid the nozzle in negotiating bends and turns. The nozzle will create a gentle pulling action on the hose. If it becomes stuck a sharp tug will usually free it. For more jetting tips check out page 12. Changing Nozzles Breather vent 1. Turn off the ball valve before removing the hose from drain. 2. Change over the nozzle as required, ensuring the replacement nozzle is fully snapped into position. 2. Attach selected drain cleaning nozzle to end of high pressure sewer hose and ensure it is fully snapped into position. WARNING: When removing hose from drain you must turn off the ball valve before or as the 2 metre mark on the hose appears. The hose has been marked for your safety and these marks must be renewed as required. Turning off the Jetter 1. Turn off the ball valve and pull the hose out of the drain. 2. De-throttle the engine then turn off. 3. Release the pressure still in the hose by opening and closing the ball valve. 4. Ensure the engine key is turned to the off position, close breather vent and turn fuel tap off. Using an Aussie Viper Mini Reel (option) 3. Place at least 2 metres of hose down the drain, use hose markings as a guide **** IMPORTANT **** WARNING... DO NOT RUN EXCESSIVE BY-PASS. Switch machine off within two minutes of ceasing operation as excessive by-pass can cause heat buildup in pump and subsequent damage. EXCESSIVE BY-PASS RUNNING VOIDS WARRANTY! 1. Ensure the ball valve on the mini reel and the ball valve on the main jetter are both off. 2. Connect sewer hose from main jetter to mini reel. 3. Connect the drain cleaning nozzle to the end of the sewer hose on the reel and ensure it is in the drain at least 2 metres. 4. Turn on the ball valve on the main jetter. 5. Pressure to the drain cleaning nozzle is now controlled by operating the ball valve on the reel. Nov 12 Aussie Cobra Series Drain Cleaner Operator s Manual Page 9

10 Aussie Pumps Operation as a High Pressure Washer 1. Fit the gun/lance assembly to the end of the sewer hose in place of the drain cleaning nozzle. 2. Start the engine. Ensure fuel tap is open, choke is fully open and turn the key or pull starter rope to start engine. It may be necessary to pull the trigger on the gun to assist the engine to start. (Refer to engine manual for more details). Adjust throttle speed as required. 3. Check for leaks in the line connections. All leaks must be fixed before using the jetter. 4. When using gun and lance, pressure begins when the gun trigger is squeezed. Turning off the Pressure Washer 1. De-throttle the engine then turn off. 2. Release the pressure still in the hose by opening and closing the gun trigger. 3. Turn off the ball valve. 4. Ensure the engine key is turned to the off position, close breather vent and turn fuel tap off. NOTE: Aussie Cobra drain cleaning jetters are fitted with an Absorbed Glass Mat dry cell battery. It may be necessary to run the jetter for at least 20 mins to recharge the battery from time to time. If the battery is flat it must be recharged using a Trickle Charge battery charger. Contact a battery specialist for further assistance. High Pressure Piston Pumps & Plumbing Your high pressure Bertolini pumping system is the heart of your drain cleaning jetter. The pump has been specially designed to be used with cold water (max 74ºC) for pipe water jetting and high pressure wash down applications. Your high pressure Bertolini piston pump is designed to move a certain amount of water per revolution by its three solid ceramic pistons. High pressure is created once the pump outlet is restricted with a nozzle. All high pressure outlet connections, hosing and equipment is rated over and above the maximum operating pressures of the pump. Do not adjust any valves on your pump; tampering will void warranty. For any malfunction of the high pressure pumping system, please contact an Aussie Pump authorised service agent. Because of safety/danger hazards with high pressure systems, only use approved genuine Aussie Cobra high pressure hoses and components when replacing or repairing your Aussie Cobra drain cleaning jetter. For guidance on this, please contact an Aussie Pump service agent IMPORTANT... Nozzle Wear Once drain cleaning nozzles or wash down nozzles have worn, pressure loss will occur. Replacement of nozzles is necessary to maintain constant and maximum efficiency of your Aussie Cobra drain cleaning jetter. Using worn nozzles will reduce unloader valve service life. Replace nozzles regularly. Proper charging is important since over or under charging will damage the battery. Always use an automatic temperature sensing voltage regulated charger. Set charger at 14.4 to 14.6 volts at 20 C. **** IMPORTANT **** WARNING... ALTERING OF HIGH PRESSURE PUMPING SYSTEM MAY RESULT IN SEVERE INJURY OR DEATH. Warranty will be void if any high pressure equipment has been altered by unauthorised persons. Over-speeding or over-pressurizing of pumping system can be very dangerous and severely reduce the life of your Aussie Cobra Drain Cleaning Jetter and may result in injury or death. Page 10 Aussie Cobra Series Skid Mount Drain Cleaner Operator s Manual Nov 12

11 Personal Protective Equipment STAY SAFE Aussie Pumps Eye Protection. Eye protection complying with AS/NZS 1337 (adequate for the purpose and of adequate fit on the person) should be worn at all times when in the vicinity of water blasting operations. Where liquid is liable to cause eye damage, full visor and goggles are recommended. Body Protection. All persons should wear suitable waterproof clothing complying with AS or AS as appropriate, having regard to the type of work being undertaken. Liquid or chemical-resistant suits should be worn where there is an assessed risk to health or of injury that can be prevented by such equipment. Hand Protection. Adequate hand protection complying with the recommendation/s of AS/NZS , AS/NZS or AS/NZS should be worn when there is an assessed risk of injury that can be prevented by such equipment. Foot Protection. All persons should wear appropriate occupational protective footwear complying with AS/NZS A metatarsal and lower leg guard should be used by water blasting operators where it is assessed that the risk of foot injury could be prevented by such equipment. AS/NZS provides guidance for the selection of footwear. Hearing Protection. Suitable hearing protection complying with AS 1270 should be worn at all times when the noise levels exceed limits set by regulatory authorities. Appropriate personal protective equipment should be worn where: hazards cannot be otherwise prevented or suitably controlled, e.g. by engineering or administration controls, total enclosure or substitution; and/or complete protection is essential, e.g. in some occupational environments with uncertain levels of hazards. Comfort, function & Safety at an affordable price For more information on personal safety protection gear rated to 500 BAR ( 7,300 psi) please contact Aussie Pumps customer service on Safety protection gear is ordered on demand. The provision and use of personal protective equipment does not reduce or replace the need for proper Occupational Health and Safety prevention measures, such as engineering or administrative controls to be undertaken. Recommendations of such preventative measures should always be fully explored before considering issue of personal protective equipment. Where personal protective equipment is issued, instruction and training should be provided regarding its correct use and maintenance. Head Protection. Where appropriate suitable head protection complying with AS/NZS 1808 should be worn. Nov 12 Aussie Cobra Series Drain Cleaner Operator s Manual Page 11

12 Aussie Pumps Operating Tips These are some of the tips and techniques that have been tried and tested over the years to make jetting easier. Hose Selection Select your hose diameter according to the size of drain you are cleaning. Pipe size Jetter Hose Selection Sewer hose size 1-4 1/ / /8 Hose Protection Once you have broken through the blockage change to a Root Ranger to clear tree roots from the sides of the drain. When using the Root Ranger, the hose must be twisted to thoroughly clear the root choke from all sides of the pipe. Guiding the Nozzle Twist your jet hose to help get it around tight bends and traps. Prevent the Root Ranger turbine from entering side channels by pushing straight through the junction as quickly as possible. Pushing the hose straight without twisting it, will help to keep the turbine on a straight path. If your hose becomes jammed, try pulling the hose hard, and then letting it go quickly so it can snap back and loosen itself. Also, try turning the jet off then pull on the hose, then turn jet back on again. Always protect your hose to prevent damage from sharp edges and rough surfaces. Use a short section of Ag pipe or conduit at the entry to the drain and feed the sewer hose down inside it. More damage is done to a hose on the entry and exit point of the drain than anywhere else. If there is a u bend, push the Ag hose down as far as the bend to protect the sewer hose from abrasion on the inside corner of the bend. If the drain entry is in a manhole or storm grate use PVC pipe or Ag pipe to create a guide for the jetter s sewer hose. Nozzle Selection Start your jetting with a long nozzle like the Predator or for smaller drains the Compressor. For really tight bends remove the quick coupler from the hose and cowling from the nozzle and screw the head directly to the hose. Quick coupler If the nozzle needs to turn into a horizontal shaft, try bending the hose back on itself so the nozzle is pointing back towards you. Push the hose down the shaft until the nozzle lines up with the junction. With nozzle in the junction, turn the jet on slowly until nozzle pulls itself up the pipe. If the nozzle does not go up the junction, it will come back up the shaft, so take extreme caution when using this method to access junction. Using the Root Ranger Nozzle Run the Root Ranger straight to the blockage without twisting the hose. Use the hose twist when you are actually cutting the roots or retrieving the hose from the blockage. This will keep it from heading up any branch drains, toilet pans and PVC capped inspection openings! For drains larger than 6 add an extension to the Root Ranger to prevent it from becoming wedged. Cowling wedged in cap stuck up a junction Page 12 Aussie Cobra Series Skid Mount Drain Cleaner Operator s Manual Nov 12

13 Aussie Pumps Nozzle Selection There are 3 main types of penetrating nozzles; the Predator, the Negotiator, and the Compressor. These three nozzles come in different configuration options The Predator Penetrator; 3 rear & 1 forward jet. A good starting choice for general drain cleaning. It has a long pointed nose for penetrating deep into a choke and blasting out the debris. (AD P3R1FC) The Negotiator; 6 rear & 1 forward jet. Designed shorter to get around tight bends and traps. It is a good multi-purpose nozzle for any drain cleaning application. (AD N6R1FC) The Compressor; 6 rear jets only. Smaller again, and assists with smaller blockages. A new extension can also be purchased for the Compressor nozzle. (AD C6R1FC) The Beaver has 2 forward firing jets, with 6 reverse thrusting jets. The 2 front jets bore deep into the choke. Ideal for dry chokes. (AD BV6R2FC) The Root Rat is extremely popular. It features 1 front jet with 6 rear jets, 3 behind the tip of the nozzle at 45º and 3 at the rear of the nozzle at 30º, enabling it to quickly penetrate the choke. (AD RR6R1FC) The Bullet is a small, but powerful nozzle used when all else fails. Although it is very effective, it should only be used on difficult chokes. It is so small it has a habit of leaving the drain. (AD B6R1FC) The Root Ranger is used to clear what the Penetrator nozzles leave behind. It has 1 rear thrust port and an optional front jet. This nozzle will clear just about anything from the drain and is the primary root cutter used by plumbers worldwide. (AD RR8TCF) Using worn nozzles will reduce unloader valve service life. NEW NOZZLES MAKE YOUR JOB EASIER ASK ABOUT OUR LATEST DRAIN CLEANING NOZZLES. ACCESS HARD TO REACH JOBS WITH THE AUSSIE VIPER MINI REEL.. remote jetter control, Connect the jetter sewer hose to the Mini reel., Use the ball valve on the reel to control the pressure to the sewer hose., Extends your reach an extra 60m., Essential kit if your jetter is ute mounted Nov 12 Aussie Cobra Series Drain Cleaner Operator s Manual Page 13

14 Aussie Pumps Operator s Hand Signals Accident Reporting This section provides a set of hand signals for communication when carrying out water jetting operations. Pressurise System Thumb pointing upwards, the rest of the hand closed. From the shoulder height the arm moves up and down. Reporting. All accidents or injuries, whether resulting in lost time or no lost time injuries, should be recorded in accordance with the recommendations of AS Incidents that result in near misses should also be recorded as a means of providing a record of significant incidents that have the potential to result in serious injury at the workplace, so appropriate measures can be implemented to minimise or eliminate these potential hazards. Depressure System. Form a fist. Move the arm back and forth at shoulder height. Personal Injuries. In the event that a person is injured by the impact of a water jet, the injury caused may appear insignificant and give little indication of the extent of the injury beneath the skin and the damage to deeper tissues. Although only a small hole may be present, quantities of water may have penetrated the skin and entered the flesh and organs causing serious injury. Medical Recommendation. If an accident occurs where pressurised water penetrates or appears to have penetrated the skin, medical assistance should be sought immediately. Immediate First Aid. Where medical examination is not immediately possible (e.g. in remote situations), appropriate basic first aid measures should be applied and the patient observed closely until medical treatment is available. Raise Pressure. First finger pointing up, the rest of the hand closed. The hand is moved in a circular motion. Medical Alert Card. All operators engaged in commercial and industrial water blasting operations should carry out an immediately accessible, waterproof medical alert card. This card should: outline the possible nature of injuries and post-accident infections that can be caused by high pressure water blasting;. Lower Pressure. First finger pointing down, the rest of the hand closed. The hand is moved in a circular motion. provide details of immediate first-aid treatment until medical treatment can be arranged; and provide the name or names of medicos (and contact phone numbers) who should be contacted for expert medical advice for the treatment of high pressure water blasting injuries. In addition, the card may also: identify the worker; and outline medical information about the worker; e.g. blood type, allergies and conditions, such as asthma. Page 14 Aussie Cobra Series Skid Mount Drain Cleaner Operator s Manual Nov 12

15 Emergency Medical Information Aussie Pumps Immediate hospital attention should be given to personnel who sustain equipment related injuries while operating the system. In such cases, it is vital that medical personnel be apprised of all facts relevant to such injuries. Therefore, all operating personnel should be provided with waterproof emergency medical tags or cards describing the nature of their work and the possibility of injury inherent in the use of a water blasting device. The tag or card should also bear the following standard notice: Service Record IMPORTANT JETTER WARRANTY VOID IF SERVICE RECORD NOT MAINTAINED Must be serviced every 6 months or 25 hours of use. Refer to page 20 for details of service schedule. Date 6 MNTH SERVICE or 25 hours 12 MNTH SERVICE or 50 hours 18 MNTH SERVICE or 75 hours 24 MNTH SERVICE or 100 hours 30 MNTH SERVICE or 125 hours 36 MNTH SERVICE or 150 hours 42 MNTH SERVICE or 175 hours 48 MNTH SERVICE or 200 hours 54 MNTH SERVICE or 225 hours 60 MNTH SERVICE or 250 hours 66 MNTH SERVICE or 275 hours 72 MNTH SERVICE or 300 hours 78 MNTH SERVICE or 325 hours 84 MNTH SERVICE or 350 hours Pump oil changed Gearbox oil changed Clean filter Check for leaks Engine serviced Check engine key for w ear Signed Nov 12 Aussie Cobra Series Drain Cleaner Operator s Manual Page 15

16 Aussie Pumps Maintenance, Service and Spares Your Aussie Eco-Clean drain cleaning jetter has been designed to give you long and trouble-free service. If however, you have a problem which cannot be resolved by referring to the Troubleshooting Guide below, or if you require spare parts or servicing, contact your local dealer (check the website for list; or call Aussie Pumps on (02) Troubleshooting Guide FAULT CAUSE REMEDY Pump running normally but Pump sucking air Check water supply and possibility of air ingress pressure low on installation Valves sticking, dirt in valves Check and clean or replace if necessary Unloader valve seat faulty Check and replace Nozzle incorrectly sized Check and replace Worn piston packing Check and replace Fluctuating pressure Valves worn Check and replace Valves blocked Check and clean out if necessary Pump sucking air Check water supply and air ingress at joints in suction line Worn piston packing Check and replace Pressure low after period of Nozzle worn Check and replace normal use Suction or delivery valves worn Check and replace Suction or delivery valves blocked Check and clean if necessary Unloader valve seat worn Check and replace if necessary Worn piston packing Check and replace if necessary Pump noisy Air in suction Check water supply and connections on suction line Broken or weak suction or delivery Check and replace if necessary valve spring Foreign matter in valves Check and clean if necessary Worn bearings Check and replace if necessary Excessive temperature of liquid Reduce temperature Presence of water in oil Oil seal worn Check and replace High humidity in air Check and change oil twice as often Piston packing worn Check and replace if necessary Water dripping from under Piston packing worn Check and replace pump Plunger retainer worn Check and replace Oil dripping Oil seal worn Check and replace if necessary By pass valve switches Leaking gun and/or pressure pipe Renew gun, seal pressure pipe repeatedly when gun is off Leaky sleeve Renew sleeve Worn out kick-back valve body Check and renew as necessary kick-back valve plate and seat Leaky seals Renew seals Leaky piston rod Defective o-ring/support ring Renew piston rod seals and examine surfaces in guide case Leaky by-pass at nominal Nozzle too small, too much water Install larger nozzle pressure Worn out by-pass valve Examine and renew as necessary Pressure gauge shows high Valve set too high above operating Adjust the unloader at the operating pressure pressure fluctuations when pressure shutting off gun Dirty valve Clean valve (removing lime deposits, etc) Grease parts before installing Engine will not start Water level low in supply tank Out of petrol Fill supply tank Fill tank with petrol Engine defect Battery flat Return to engine service agent Use a trickle charge recharging unit only or contact a battery specialist **** WARNING **** CHECK OIL LEVEL IN PUMP REGULARLY. DO NOT OVERFILL. Page 16 Aussie Cobra Series Skid Mount Drain Cleaner Operator s Manual Nov 12

17 Pump Kits PUMP PARTS Aussie Pumps RAL 2035H (King Cobra Honda) RAL 2535H (King Cobra Vanguard & Kohler) Kit Part No. Description Pieces No. 123 BKIT123 VALVE KIT BKIT164 SEAL KIT MINOR BKIT165 SEAL KIT MAJOR BKIT146 OIL SEAL KIT 3 67 BKIT67 CAP KIT BKIT147 O-RING & GLASS KIT 11 PUMP PARTS RAS 4482 (Python) Kit Part No. Description Pieces No. 148 BKIT148 VALVE KIT BKIT153 SEAL KIT MINOR BKIT152 SEAL KIT MAJOR BKIT146 OIL SEAL KIT 3 67 BKIT67 CAP KIT BKIT147 O-RING & GLASS KIT 11 Order the right part first time specify the pump model number when ordering parts. Full parts breakdowns available online Nov 12 Aussie Cobra Series Drain Cleaner Operator s Manual Page 17

18 PUMP PARTS TTL 2030 (Cobra) Aussie Pumps Kit No. Part No. Description Pieces 127 BKIT127 Full Oil seal & Sight Glass kit BKIT123 Valv e Kit BKIT95 Seal Kit Minor BKIT96 Seal Kit Major BKIT37 Oil Seal Kit 3 67 BKIT67 Valv e cap kit 12 Order the right part first time specify the pump model number when ordering parts. Full parts breakdowns available online Aussie Blasters Service Fundamentals covers servicing of high pressure piston pumps in detail. Download this useful service guide from the Aussie website or call for your FREE copy. Page 18 Aussie Cobra Series Skid Mount Drain Cleaner Operator s Manual Nov 12

19 Replacement Parts Aussie Pumps P O D E G B A E C N N J O M K Position Part No Description Cobra King Cobra Py thon Pump BTTL2030 BERTOLINI PUMP (4,300 PSI, 20 LPM) x BRAL2035 BERTOLINI PUMP (5,000 PSI, 20 LPM) x (Honda) BRAL2535 BERTOLINI PUMP (5,000 PSI, 25 LPM) x (Vanguard, Kohler) BRAS4482 BERTOLINI PUMP (4,300 PSI, 31 LPM) x Gearboxes B B GEARBOX (1" PTO) x B GEARBOX (1 1/8" PTO) x x Unloader C BVB350 UNLOADER VALVE (5100 PSI) x x BVB80/280 UNLOADER VALVE (4,000 PSI) x Safety Valves D MPA PSI SAFETY VALVE x MPA PSI BVS350 SAFETY VALVE x x Pump Filter model used depends on space available AYSTRAINER3/4 BRASS Y STRAINER ¾ x x x E M ¾ F LINE STRAINER 80 MESH x x x JP15-1RLA60P-1V 5 CARTRIDGE FILTER 60 MICRON x x x Fuel Tank (optional) Not shown AFUELTANKCOBRA 12 LITRE FUEL TANK x x x Gauge G AGCDR PSI GAUGE x x x Nozzles (in end of lance) K C915 _ M HP NOZZLE (15º ANGLE, TIP SIZE ref er to table) Lance M C M SS SINGLE LANCE x x x Gun & Couplers N M AL50 4,000 PSI RATED GUN WITH EXTENSION x x x M ML2002 5,000 PSI RATED GUN WITH EXTENSION x x x O C ¼ QUICK COUPLER FITS GUN TO THE LANCE x x x HP Sewer Hose AHOSER8 1/4 60M HOSE R8 1/4 60M 5000PSI x x Hose Reels (optional) ADHR50150D HOSE REEL 5000 PSI x x Engine Accessories Not shown AENGINEMOUNT300 ENGINE MOUNT (4 NEEDED) x x x Not shown ABATTERYKEN DRY CELL BATTERY x x x Nov 12 Aussie Cobra Series Drain Cleaner Operator s Manual Page 19

20 Aussie Pumps LOOK AFTER YOUR MACHINE AND IT WILL LOOK AFTER YOU. Warnings OVER SPEEDING Do not operate machine at over 3200rpm (engine speed - preset). Over-speeding can cause serious pump damage and will void warranty. EXCESSIVE BY-PASS Do not run on excessive by-pass. Switch machine off within two minutes of ceasing operation as excessive by-pass can cause heat build-up in pump and subsequent damage. Excessive by-pass running voids warranty. This does not apply to machines fitted with supply tanks. HIGH PRESSURE SETTING The high pressure pump is factory set to operate at its rated pressure. DO NOT ADJUST. Tampering with the pressure regulator will void warranty and can be DANGEROUS. CHECK NOZZLES & COUPLINGS WEEKLY, clean after each use. If pressure drops off, check nozzle for wear. Nozzles should be replaced on a regular basis (every month for machines in regular use, every three months for machines used intermittently). Using the machine with the incorrect nozzle size or worn nozzle will void warranty and can be DANGEROUS to the operator. Pressure Cleaner Daily Check List 1. Check pump & gearbox oil level. 2. Check engine oil level. 3. Check nozzle for wear. 4. Check all high pressure components for leaks, damage, wear or corrosion: (a) Gun/Lance. (b) HP hose & connections (c) All fittings. 5. Check water filter and clean if necessary. 6. Check unloader & safety valve for leaks. Six Month (25 hours of use) Regular Service All professional machines need to be thoroughly serviced every six months or 25 hours of use, whichever comes first. The service involved should include the engine manufacturer s recommendations (see separate Engine Manual) and the following: 1. Change pump & gearbox oil. 2. Change engine oil if required (refer to engine manual for schedule). 3. Check filter for foreign debris. 4. Check unloader & safety valve for leaks. 5. Check all HP components, including the hose, for leaks, damage, wear or corrosion. Replace if necessary. 6. Replace nozzles. 7. Check gearbox to engine key for wear, if key is worn see your local Aussie Eco-Clean Service Department. NB. Damage generated by worn keys is not covered by warranty! AUSTRALIAN PUMP INDUSTRIES 7 Gladstone Road, CASTLE HILL NSW 2154 PO Box 6164, Baulkham Hills Business Park NSW 2153 Ph: (02) info@aussiepumps.com.au Page 20 Aussie Cobra Series Skid Mount Drain Cleaner Operator s Manual Nov 12